Chapter 6. Food Production

Transcription

1 Chapter 6 Food Production

2 Functional Subsystem: Food Production Food production is the preparation of menu items in the needed quantity & with the desired quality. Quantity Distinguishes foodservices production from home or family food preparation. Quality Aesthetic, nutritional, & microbiological safety aspects of a food product.

3 Production Subsystem Objectives Primary: Transform human, material, facility, & operational resources into outputs. Secondary: Product/service characteristics Process characteristics Product/service quality Efficiency: Effective employee relations & cost control of labor Cost control of materials Cost control of facility use Customer service: Produce quantities to meet expected demand Meet delivery date for products or services

4 Production Decisions Includes forecasting, planning, & production scheduling. Synthesis of quantity, quality, & cost objectives. Product characteristics Production process characteristics Establishment of standards of quality

5 Production Forecasting Primary result of forecasting should be customer satisfaction. Production Demand Overproduction Production of more food than is needed for service. Underproduction Production of less food than is needed for service

6 Production Forecasting Quantity Demand Estimate number of customers or the number of servings. Essential to use suitable forecasting model. Examples: Historical records Intuition Complex models requiring large amounts of data

7 Production Forecasting Historical Records Effective production records should include: Date & day of the week Meal or hour of service Notation of special event, holiday, & weather conditions Food items prepared Quantity of each item prepared Quantity of each item served Provide fundamental base for forecasting quantities when the same meal or menu item is repeated.

8 Forecasting Models Criteria for a Model: Cost expenses of both development & operation. Required accuracy accuracy of its predictions of future occurrences. Relevancy of past data relationship of past & future data. Forecasting lead time length of time into future the forecasts are made. Underlying pattern of behavior actual occurrences follow some known pattern.

9 Types of Models Most common model categories: Time series Casual Subjective Trends & seasonality in the data must be considered.

10 Time Series Model Assumption that actual occurrences follow an identifiable pattern over time. Suitable for short-term forecasts. Frequent time series models: Moving average forecasting model Exponential smoothing forecasting model

11 Moving Average Forecasting Model First point: average of number of portions sold for the last five or more times the menu item was offered. Second point: average of dropping the first number & adding the most recent number of portions sold to the bottom of the list. Continue process for all data.

12 Moving Average Forecasting Model

13 Exponential Smoothing Forecasting Model New forcast= judgment last factor demand + 1 judgment last factor forecast All past data are considered in smoothing process. More recent data are given more weight. Requires only a few pieces of data to update a forecast. Easily programmed & is inexpensive to use. Rate at which the model responds to change can be adjusted mathematically.

14 Casual Model Assumption that an identifiable relationship exists between the item being forecast & other factors. High costs for development & use. Popular for medium- & long-term forecasts.

15 Regression Analysis Forecasting Models Most commonly adapted. Includes: Dependent variables items being forecast. Independent variables factors determining the value of the dependent variables. Requires a history of data to permit plotting over time.

16 Subjective Model Used when relevant data is scarce or patterns & relationships between data do not tend to persist over time. Delphi technique Market research Panel consensus Visionary forecast Historical analogy

17 Production Scheduling Time sequencing of events required to produce a meal. Planning stage: Forecasts are converted into the quantity of each menu item to be prepared. Distribution of food production to supervisors in each work center. Action stage: Supervisors prepare a production schedule. Items are assigned to specific employees.

18 Production Schedule Should include: Employee assignments Preparation time schedule Menu item Over- & underproduction Quantity to prepare: forecast amount for each menu item. Substitutions Actual yield: portion count produced by the recipe. Additional assignments Special instructions & comments Pre-preparation

19 Production Meetings Should be held daily with employees in the production unit. Employees encouraged to discuss the effectiveness of the schedule. Free discussion of work loads. Conclude with discussion of the production schedule for the following three meals.

20 Ingredient Control Begins with purchasing, receiving, & storage of foods. Continues through forecasting & production. Ingredient assembly area designed for measuring ingredients. Standardized recipes provides assurance that standards of quality will be consistently maintained.

21 Advantages of Centralized Ingredient Assembly Contributes to the cost reduction & quality improvement. Redirection of cooks skills away from collecting, assembling, & measuring ingredients to production, garnishing, & portion control. More efficient use of labor.

22 Centralized Ingredient Control Control of unused portions is facilitated because storage is located centrally rather than in various work units. Ability to combine tasks for two or more recipes using similar ingredients.

23 Function of the Ingredient Room Primary function is to coordinate assembly, pre-preparation, measuring, & weighing of the ingredients. Availability of appropriate equipment will help determine the activities to be performed.

24 Ingredient Room Organization Should be located between the storage & production areas. Necessary equipment includes: Refrigeration Water supply Trucks or carts for assembly & delivery Worktable or counter Scales

25 Ingredient Room Staffing Employees must be: Literate Able to do simple arithmetic Familiar with storage facilities Responsible for receiving, storage, & ingredient assembly.

26 Ingredient Room Staffing Ingredient assembly personnel considerations: Size of operation Frequency & time of deliveries Size of ingredient room & location of other storage areas Type, number, & complexity of menu items Number of workstation to be supplied Schedule for delivery of ingredients to production & serving areas Extent of pre-preparation performed in ingredient assembly area

27 Future of Ingredient Rooms Centralized or food factories are being used for procurement & production. Prepared menu items are distributed to several remote areas for final preparation.

28 Recipe Formula by which weighed & measured ingredients are combined in a specific procedure to meet predetermined standards. Written communication tool that passes information from the foodservice manager to the ingredient room & production employees. Quality & quantity control tool.

29 Recipes Recipes include: Name of food item Total yield Portion size & number of portions Cooking time & temperature List of ingredients in order of use Amount of each ingredient by weight, measure or count Procedures Panning or portioning information Food safety (HACCP) guidelines.

30 Format All recipes in an operation should be in the same format. Common large quantity formats: Block format Complete block format Modified block format

31 Block Format Ingredients listed on left side of recipes. Procedures directly opposite ingredients on right side.

32 Complete Block Format Horizontal lines separate each group of ingredients with procedures. Vertical lines separate the ingredient, amount, & procedure columns.

33 Modified Block Format Most common Horizontal lines separate the required ingredients for each procedure.

34 Format Additional information often added at bottom or on back: Approximate nutritive values per portion Variations on the recipe Special serving instructions Storage requirements before & after service

35 Format Recipes should be in large print easily readable from inches. Recipe name should be in bold letters. Major categories (breads, meat, salad, etc.) may be color coded to make identification easier. KEEP BACKUP OF RECIPES!!!

36 Standardization Ideal to have recipes that consistently deliver the same quantity & quality product when followed precisely. Recipe standardization process of tailoring a recipe to suit a particular purpose in a specific foodservice operation. Requires repeated testing.

37 Justification Advantages for using standardized recipes: Promote uniform quality of menu items. Promote uniform quantity of menu items. Encourage uniformity of menu items. Increase productivity of cooks. Increase managerial productivity. Save money by controlling overproduction.

38 Justification Advantages (cont.): Save money by controlling inventory levels. Simplify menu item costing. Simplify training of cooks. Introduce a feeling of job satisfaction. Reduce anxiety of customers with special dietary needs.

39 Three Phases of Recipe Standardization Standardized recipes: Developed for use by a foodservice operation. Found to produce consistent results & yield each time prepared.

40 Three Phases of Recipe Standardization

41 Recipe Verification Review components of the recipe Recipe title Recipe category Ingredients Weight/measure for each ingredient Preparation instructions Cooking temperature & time Portion size Recipe yield Equipment to be used

42 Recipe Verification Make the recipe Verify the recipe yield Record changes to the recipe

43 Product Evaluation Informal Evaluation: Visual appearance Flavor Ability to obtain ingredients Cost per serving Labor time Availability of equipment Employee skill

44 Product Evaluation Formal Evaluation Select group of staff members & customers as a taste panel. Choose or develop an evaluation instrument. Prepare sample recipe. Set up sampling area. Sampling & evaluation of products. Summarize results. Determine future plans for the recipe.

45 Quantity Adjustment Methods include: Factor method Percentage method Direct reading measurement tables Computer software also available

46 Factor Method Change ingredient amounts to whole numbers & decimals. Divide desired yield by the recipe yield to determine the conversion factor. Multiply all recipe ingredients by the conversion factor.

47 Factor Method Reconvert decimal unit back into pounds & ounces or quarts & cups. Round off amounts to quantities simple to weigh or measure. Check math for possible errors.

48 Percentage Method Convert all ingredients from measure or pounds & ounces to tenths of a pound. Total the weight of ingredients in a recipe after each ingredient has been converted to weight in the edible portion. Calculate the percentage of each ingredient in the recipe in relation the total weight. Check the ratio of ingredients.

49 Percentage Method Establish the weight needed to provide the desired number of servings. Add handling loss to the weight needed. Multiply each ingredient percentage number by the total weight to give the exact amount of each ingredient needed. Convert to pounds & ounces or to measures.

50 Direct Reading Measurement Tables Quick to use & require no mathematical calculations. Used to adjust weight & volume of ingredients in recipes that are divisible by 25.

51 Adapting Home-Size Recipes Special considerations are necessary: Know exactly what ingredients are used & in what quantity. Make the recipe in original home-size quantity. Evaluate the product for acceptability. Proceed in incremental stages in expanding the recipe.

52 Adapting Home-Size Recipes Special considerations are necessary: Determine handling or cooking losses (5%- 8% loss is typical). Check ingredient proportion against a standard large quantity recipe. Evaluate products using taste panels.

53 Quantity Food Production Involves: Control of ingredients Production methods Quality of food Labor productivity Energy consumption. Sweet Spot point of best value at lowest cost.

54 Objectives of Food Production Primary reasons to cook food: Destruction of harmful microorganisms Increased digestibility Change & enhancement of flavor, form, color, texture, & aroma

55 Heat Transfer Conduction the transfer of heat through direct contact from one object to another. Convection distribution of heat by the movement of liquid or vapor.

56 Heat Transfer Radiation generation of heat energy by wave action within an object. Induction use of electrical fields to excite the molecules of metal cooking surfaces.

57 Moist Heat Use of water or steam for the cooking process. Simmering or stewing cooking in a liquid that is boiling gently (185º-205º F). Poaching cooking in a small amount of liquid that is hot but not bubbling (160º-180º F). Blanching cooking an item partially & briefly. Braising cooking food in a small amount of liquid, usually after browning it. Steaming cooking food by exposing them to direct steam.

58 Dry Heat Use of dry air, hot metal, radiation, or a minimum amount of hot fat for the cooking process. Includes: Broilers heat source 3-6 from food. Deep Fat Fryers food immersed in tank of oil heated by gas or electricity. Ovens combination of conduction, convection, & radiation.

59 Multifunction Equipment Combination of several pieces of equipment to increase space in production area. Combi-oven includes convection and/or steam Tilting skillet combines range, griddle, kettle, stock pot, & frying pan. Convection/microwave oven - includes convection and/or microwave

60 Production Controls Quality control assuring day-in, day-out consistency in each product. Quantity control producing exact amount needed. Controls: Time & Temperature Control Product Yield Portion Control

61 Energy Use Direct energy energy expended to produce & serve menu items. Indirect energy energy expended to facilitate functions that use direct energy.

62 Energy Conservation ENERGY STAR : partnership which promotes energy efficiency in buildings & homes. Energy conservation checklist: Food Preparation Refrigeration Lighting HVAC Sanitation & water Office & Administration

63 Energy Management Should include: Record-keeping system for tracking utility costs & monitoring equipment use. Employee training Use of energy efficient equipment